Metal container for holding food while cooking and method of making same

ABSTRACT

A metal can for holding food during cooking is provided. The metal can includes a metal sidewall having an upper end, a lower end and a midpoint. The metal sidewall has an inner surface defining an interior cavity of the can configured to hold food during cooking. The metal can includes a metal can end coupled to the lower end of the sidewall and a metal insert located within the interior cavity of the can. The metal insert includes a planar disc and an upstanding insert sidewall extending from a peripheral edge of the disc portion, and a radially outward facing surface of the insert sidewall engages the inner surface of the metal sidewall.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a continuation of PCT/US2012/045764 titled, “METALCONTAINER FOR HOLDING FOOD WHILE COOKING AND METHOD OF MAKING THE SAME,”filed Jul. 6, 2012, which claims the benefit of U.S. Provisional PatentApplication No. 61/505,878 titled “ROASTING CAN AND METHOD OF MAKING THESAME,” filed Jul. 8, 2011, which are incorporated herein by reference intheir entireties.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of metal containerswhich are heated while food is in the containers. The present inventionrelates specifically to a metal container configured to hold food duringcooking and more specifically to a metal container that holds amaterial, such as coffee beans, during roasting.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to a metal can for holding foodduring cooking including a metal sidewall having an upper end, a lowerend and a midpoint. The metal sidewall has an inner surface defining aninterior cavity of the can configured to hold food during cooking. Themetal can includes a metal can end coupled to the lower end of thesidewall and a metal insert located within the interior cavity of thecan. The metal insert including a planar disc and an upstanding insertsidewall extending from a peripheral edge of the disc portion, and aradially outward facing surface of the insert sidewall engages the innersurface of the metal sidewall. The metal can further includes acircumferential bead formed in the metal sidewall, and thecircumferential bead is located between the lower end and the midpointof the metal sidewall. The circumferential bead extends radially inwarddefining a downward facing surface generally facing the lower end of thesidewall, and the insert sidewall includes an upward facing surfacegenerally facing the upper end of the metal sidewall, and the upwardfacing surface of the insert sidewall engages the downward facingsurface of the circumferential bead to hold the metal insert below thecircumferential bead.

Another embodiment of the invention relates to a metal can for holdingcoffee beans during roasting including a metal sidewall having an upperend and a lower end. The metal sidewall has an inner surface whichdefines an interior cavity of the can that is configured to hold rawcoffee beans during roasting. A can end is coupled to the lower end ofthe sidewall, and at least a portion of the sidewall is tapered betweenthe upper end and lower end of the sidewall.

Another embodiment of the invention relates to a stirring insertconfigured to be coupled to the inner surface of a sidewall of a metalcan configured to hold raw coffee beans during roasting. The inserthaving a body disc and a sidewall positioned at the periphery of thebody disc extending away from the body disc. The stirring insert alsoincluding a stirring finger extending from the body disc.

Another embodiment of the invention relates to a method for producing astirring insert for a coffee roasting can. The method includes the stepsof providing a metal blank and forming a body disc and an upstandingsidewall from the metal blank. The upstanding sidewall is positioned atthe peripheral edge of the body disc. The method includes cutting a slotthrough the body disc. The slot defines the peripheral edge of astirring finger. The method includes pushing the stirring finger upwardsuch that the stirring finger extends away from the body disc.

Yet another embodiment of the invention relates to a method forproducing a coffee roasting can including the steps of providing arectangular metal blank and forming a cylinder from the metal blank. Thecylinder is shaped to form a tapered can sidewall, the sidewall havingan open upper end, an open lower end and an upward facing surfacelocated along the inner surface of the sidewall. The method includescoupling an end wall to the lower end of the sidewall and inserting astirring insert through the open upper end of the sidewall such that theinsert seats against the upward facing surface of the sidewall.

Alternative exemplary embodiments relate to other features andcombinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingfigures, wherein like reference numerals refer to like elements inwhich:

FIG. 1 is a cross-sectional view of a container and insert according toan exemplary embodiment.

FIG. 2 is a cross-sectional view of a container according to anexemplary embodiment.

FIGS. 3A-3D show production of the container insert of FIG. 1 accordingto an exemplary embodiment.

FIGS. 4A-4F show production of the container of FIG. 1 according to anexemplary embodiment.

FIG. 5 shows nesting of two containers according to an exemplaryembodiment.

FIGS. 6A-6E show containers configured to engage an insert according tovarious exemplary embodiments.

FIG. 7 is a cross-sectional view of a two piece container according toan exemplary embodiment.

FIGS. 8A-8C shows the production of the two piece container of FIG. 7according to an exemplary embodiment.

FIGS. 9A and 9B show a container according to an exemplary embodiment.

FIG. 10 is a container according to an exemplary embodiment.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplaryembodiments in detail, it should be understood that the presentapplication is not limited to the details or methodology set forth inthe description or illustrated in the figures. It should also beunderstood that the terminology is for the purpose of description onlyand should not be regarded as limiting.

Referring generally to the figures, various metal containers and methodsfor making the same are shown according to exemplary embodiments. Themetal containers disclosed herein may be used to hold food duringheating or cooking. In some embodiments, the containers discussed hereinare configured for use in a consumer or home-use coffee roastingappliance. The coffee roasting appliance is configured to automaticallyroast raw or “green” coffee beans in relatively small quantities forhome coffee brewing purposes. In operation, a metal container or cancontaining raw coffee beans is received within a cavity of the coffeeroasting appliance. The coffee roasting appliance includes one or moreheating elements that deliver heat to the metal can and to the coffeebeans in order to roast the coffee beans within the can. The coffeeroasting appliance may be configured to rotate the metal can containingcoffee beans during roasting. As the can rotates, the beans within thecan are agitated helping to ensure even roasting of the beans within thecan. When the beans are roasted, the can containing the now roastedbeans is opened, and the beans are ground to make coffee from thefreshly roasted beans. The metal containers discussed herein areconfigured to hold raw or unroasted coffee beans and are suitable forholding the beans during roasting using a consumer or counter-top coffeeroasting appliance as discussed above. Further, the metal containersdiscussed herein may be used in other heating or cooking processes, suchas a retort process, in which other food items (e.g., vegetables, meats,sauces, fruits, etc.) are cooked within the metal containers.

Referring to FIG. 1, a metal container or can 10 is shown according toan exemplary embodiment. Can 10 is shown as a three-piece can andincludes a sidewall 12. Can 10 includes an open upper end 14 and a lowerend 16. Can 10 includes a lower can end wall 18 coupled to sidewall 12at lower end 16. In FIG. 1, upper end 14 of can 10 is shown before anupper can end is attached to sidewall 12. Can 10 may be shipped from thecan manufacturing facility with upper end 14 left open such that can 10may be filled with raw coffee beans. After can 10 is filled with coffeebeans, a can end may be coupled to sidewall 12 at upper end 14 via adouble seam to seal the can.

As shown in FIG. 1, sidewall 12 of can 10 is a tapered sidewall thattapers from upper end 14 toward lower end 16. As such, the diameter ofcan 10 decreases along the axial length of sidewall 12 from upper end 14to lower end 16. The taper of sidewall 12 may allow empty cans 10 to benested to conserve space during the shipment of empty cans 10 to thepacking or filling facility. Further, in one embodiment, the cavity ofthe countertop coffee roasting appliance that receives can 10 may alsoinclude a tapered inner surface. In this embodiment, the taper ofsidewall 12 matches the tapered inner surface of the cavity such that acan having the corresponding taper fits securely within the cavity ofthe roasting appliance. In one embodiment, lower can end 18 may includea vent structure (e.g., one or more holes or apertures through lower canend 18) that allows gases produced during roasting of the coffee beansto escape can 10. In one such embodiment, the vent structure may be ahole or perforation through lower can end 18 that is sealed with a foilor polymer covering. The foil seals the perforation during filing,storing, transport, etc. of can 10. However, the foil seal is adheredsuch that internal can pressure during roasting will rupture the foilseal allowing gases to escape can 10 during roasting. In anotherembodiment, lower can end 18 is a solid metal can end configured tohermetically seal the bottom of the sidewall. In such embodiments, lowercan end does not include a vent structure or covering foil.

In the embodiment of FIG. 1, sidewall 12 includes three sections, anupper section 20, a middle section 22 and a lower section 24. Uppersection 20 and lower section 24 are substantially cylindrical sectionsof sidewall 12 with the diameter of lower section 24 being less than thediameter of upper section 20. Middle section 22 extends between thelower end of upper section 20 and the upper end of lower section 24.Middle section 22 is a continuously tapered section. As such, thediameter of can 10 at middle section 22 continuously or smoothlydecreases along the axial length of middle section 22 from upper section20 toward lower section 24. A radially inwardly extending transitionsection 26 is located at the lower end of middle section 22 and joinsmiddle section 22 to lower section 24.

Can 10 includes an insert 30. Insert 30 may be made of metal and issupported within can 10. Insert 30 includes an insert body, shown asdisc shaped center portion 32 and an upstanding skirt or sidewall 34that extends upward from the peripheral edge of disc 32. In theembodiment shown in the figures, insert 30 is shaped as a circular cupshaped insert having a cross-section that matches the circularcross-section of can 10. However, insert 30 need not be circular and canbe any shape suitable for coupling within a roasting can. In oneembodiment, the cross-sectional shape of insert 30 matches thecross-sectional shape of can 10 to provide a relatively tight fitbetween insert 30 and the inner surface of sidewall 12. For example, ifthe roasting can is a polygonal prism (e.g., as shown in FIG. 9), thecross-section of insert 30 may also be polygonal.

As shown in FIG. 1, insert 30 is positioned within can 10 such thatinsert 30 separates the inner cavity of can 10 into an upper cavity 36and a lower cavity 38. After filling can 10, upper cavity 36 holds thecontainer contents (e.g., coffee beans, other food, etc.), and lowercavity 38 may hold one or more material which is separated from thecoffee beans by insert 30. In one embodiment, lower cavity 38 mayinclude a filter material that filters odor of the coffee duringroasting and/or that catches material that is shed from the coffee beansduring roasting.

Insert 30 also includes a pair of upstanding paddles or fingers 40.Fingers 40 act to stir or agitate beans located within can 10 as thecoffee roasting appliance rotates can 10 during roasting. The agitationor stirring-action provided by fingers 40 may help to allow for evenroasting of the coffee beans within can 10. In one embodiment, fingers40 extend upward from disc 32 toward upper end 14 and are substantiallyperpendicular to insert disc 32. Fingers 40 are substantially planarprojections including parallel side edges 42 and a curved upper edge 44.In one embodiment, disc 32, sidewall 34 and fingers 40 are formed from acontiguous piece of material. In this embodiment, insert 30 is generallycup shaped with sidewall 34 extending away from disc 32 such that bothsidewall 34 and fingers 40 are positioned on the same side of disc 32.In other embodiments, sidewall 34 may extend downward from theperipheral edge of disc 32 such that sidewall 34 and fingers 40 arepositioned on opposite sides of disc 32.

In the embodiment shown, transition section 26 provides a shouldersection having a generally upward facing surface against which the lowersurface of insert 30 is seated. In this manner, the upward facingsurface of transition section 26 is positioned along sidewall 12 to seatinsert 30 properly such that upper cavity 36 and lower cavity 38 are ofthe desired size. In one exemplary embodiment, the upward facing surfaceprovided by transition section 26 is substantially perpendicular tosidewall 12 and is substantially parallel to a plane defined by lowercan end 18. However, it should be understood that the upward facingsurface against which insert 30 seats may be angled relative to sidewall12 at an angle sufficient to support insert 30 at a fixed position alongsidewall 12.

In addition to seating against the upward facing surface of transition26, insert 30 may be configured to engage sidewall 12 to resist movementrelative to sidewall 12. For example, in the embodiment of FIG. 1, theradially outermost surface of insert sidewall 34 engages the innersurface of sidewall 12 forming a friction fit between insert 30 andsidewall 12 sufficient to hold insert 30 in place during transport,filling and use of can 10. In the embodiment shown in FIG. 1, insertsidewall 34 is substantially perpendicular to disc 32. However, in someembodiments, sidewall 34 of insert 30 may be angled outwardly away fromdisc 32 to increase or optimize the friction fit between insert sidewall34 and the inner surface of can sidewall 12.

With sidewall 12 being tapered, the diameter of insert 30 may beselected such that insert 30 engages the sidewall at the desiredposition along the tapered section of sidewall 12. For example, in oneembodiment, the diameter of insert 30 as well as the positioning oftransition section 26 are selected to set the relative sizes of upperchamber 36 and lower chamber 38. In various embodiments, the height oflower chamber 38 accounts for less than half of the height of can 10,specifically accounts for less than a third of the height of can 10, andmore specifically accounts for less than a quarter of the height of can10. In various embodiments, transition section 26 is positioned suchthat less than half of the length of sidewall 12 is below transitionsection 26, such that less than a third of the length of sidewall 12 isbelow transition section 26, and more specifically such that less than aquarter of the length of sidewall 12 is below transition section 26.

Referring to FIG. 2, a view of an exemplary embodiment of can 10 isshown including labeled dimensions as described below. As shown, uppersection 20 includes an inner diameter D1, shoulder 26 includes an innerdiameter D2 and an outer radius of curvature R1, sidewall 12 includes aheight H1 and lower section 24 includes an inner diameter D3 and aheight H2. In various embodiments, D1 is between 2 and 4 inches,specifically is between 2.5 and 3.5 inches, and more specifically is2.872 inches. In various embodiments, D2 is less than D1 and is between2 and 4 inches, specifically is between 2 and 3 inches, and morespecifically is 2.576 inches. In various embodiments, D3 is less than D1and is between 2 and 4 inches, specifically is between 2 and 3 inches,and more specifically is 2.578 inches. In various embodiments, H1 isbetween 3.5 and 5.5 inches, specifically is between 4 and 5 inches, andmore specifically is 4.520 inches. In various embodiments, H2 is lessthan one half of H1 and is between 0.5 and 2 inches, specifically isbetween 0.7 and 1.7 inches, and more specifically is 1.197 inches. Invarious embodiments, R1 is between 0.01 and 0.1 inches, specifically isbetween 0.03 and 0.09 inches, and more specifically is 0.06 inches. Invarious embodiments, the dimensions and ranges of dimensions discussedabove may be plus or minus a tenth of an inch. In other embodiments, thedimensions and ranges of dimensions discussed above may be plus or minusa half of an inch. FIG. 2 also shows the taper angle A of middle section22 of sidewall 12. As shown angle A is the angle between the middlesection 22 and the longitudinal axis of sidewall 12. In variousembodiments, angle A is between 0 degrees and 10 degrees, specificallyis between 2 degrees and 8 degrees, and more specifically is between 4degrees and 6 degrees. In one embodiment, angle A is approximately 5degrees.

Referring to FIG. 3A-3D, a schematic representation of the steps of theformation of insert 30 is shown according to an exemplary embodiment,and each FIG. 3A-3D, shows a top plan view and a schematic sectionalview of the insert during different steps of formation. As shown in FIG.3A, a metal disc or slug 50 is provided. As shown in FIG. 3B, a cup 52is formed from slug 50. During the step shown in FIG. 3B, disc 32 andsidewall 34 of insert 30 are formed. As shown in FIG. 3C, two U-shapedslots 54 are cut into disc 32 forming finger precursor 56. In oneembodiment, U-shaped slots 54 may be cut into disc 32 using a press orpunch type cutting tool, and in this embodiment, insert 30 may besupported from below to resist downward deformation that may otherwiseoccur during cutting. As shown in FIG. 3D, finger precursors 56 arepushed upward bending at the edge 60 attached to disc 32 to form fingers40 and to complete formation of insert 30. As shown in FIG. 3D, afterfingers 40 are pushed upward, two apertures 58 through disc 32 are leftin the place where finger precursors 56 previously were. In oneembodiment, fingers 40 and consequently apertures 58 are sized to begenerally smaller than a coffee bean such that coffee beans aremaintained in upper cavity 36 and are not permitted to pass throughapertures 58. In addition, a screen or mesh material may be positionedover apertures 58 to limit or prevent material located within lowercavity 38 of can 10 from passing into upper chamber 36. In one suchembodiment, the screen material may be adhered to the bottom surface ofdisc 32 extending over apertures 58 after fingers 40 are formed.

Referring to FIG. 4A-4F, a schematic representation of the steps of theprocess of making can 10 is shown according to an exemplary embodiment.As noted above, can 10 is a three piece can having a tapered sidewall12. To form can 10, as shown in the step of FIG. 4A, a rectangular sheetof metal or can blank 70 is provided. As shown in the step of FIG. 4B,can blank 70 is rolled, and the free edges 74 of blank 70 are weldedtogether forming weld 71. When weld 71 is formed, a cylindrical can body72 is formed from blank 70. As shown in the step of FIG. 4C, cylindricalcan body 72 is stretched radially causing the overall length of can body72 to decrease. During the step shown in FIG. 4C, can body 72 isstretched to form an upper expanded sidewall section 76 and a lowersidewall section 78. In this embodiment, the diameter of upper sidewallsection 76 is greater than the diameter of lower sidewall section 78.Further, in addition to stretching, upper flange 80 and lower flange 82are formed at the upper edge and lower edge, respectively, of can body72 as shown in FIG. 4C. Upper flange 80 and lower flange 82 are used toform a double seam formed by interlocking and compressing the flanges 80and 82 with the peripheral edge of the upper and lower can ends,respectively. The double seam couples the can ends to the can sidewallto complete the can and also forms a hermetic seal.

During the step shown in FIG. 4D, can body 72 is shaped to provide boththe tapered sidewall 12 of can 10 and transition section 26. Thedifferent diameters of sections 76 and 78 formed in the step of FIG. 4Care specifically selected to facilitate formation of the desired taperof sidewall 12 during the shaping step shown in FIG. 4D. In oneembodiment, an expanding mandrel may be used during the step shown inFIG. 4D to form tapered sidewall 12 from can body 72.

During the step shown in FIG. 4E, lower can end 18 is coupled tosidewall 12 by forming a double seam 83 from lower flange 82 and theperipheral section of material of the lower can end. During the stepshown in FIG. 4F, insert 30 is moved through open end 14 and is seatedagainst the upward facing surface of transition 26. In one embodiment,insertion of insert 30 into can 10 may occur at the can manufacturingfacility. In another embodiment, insertion of insert 30 into can 10 mayoccur at the coffee bean packing or filling facility. In thisembodiment, one or more cans 10 without an internal insert 30 (e.g., asshown in FIG. 4E) and one or more separate inserts 30 may be shipped tothe coffee bean packing facility. Further, as shown in FIG. 5, if can 10is shipped from the can manufacturer without insert 30 being positionedinside can 10, multiple cans 10 may be nested together. This nesting,when shipping cans 10, may reduce the overall volume of the cans beingshipped. FIG. 5 shows the nesting of a first can, shown as can 10′ (theoutline of can 10′ is shown in dashed lines in FIG. 5), inside a secondcan 10. In the nesting arrangement, inner can 10′ seats againsttransition 26. Thus, transition 26 may facilitate nesting of multiplecans 10 by ensuring sufficient spacing between the lower surface of thelower end wall of the inner can and the upper surface of the lower endwall of the outer can.

In various embodiments, can 10 may include one or more featuresconfigured to engage insert 30 to properly position insert 30 relativeto the bottom end wall of can 10 and to help secure insert 30 within can10. In various embodiments, the feature configured to engage insert 30is positioned above the lower can end and below the vertical mid-pointof sidewall 12 such that the portion of the height of sidewall 12 belowthe insert is less than half of the height of sidewall 12. For example,as discussed above regarding FIG. 1, transition section 26 includes anupward facing surface against which insert 30 is seated, and theupstanding sidewall 34 of insert 30 provides a friction fit between theouter surface of sidewall 34 and the inner surface of sidewall 12 tosecure insert 30 within can 10.

However, in other embodiments, the upward facing surface against whichinsert 30 is seated may be provided by a structure other than transition26, and can 10 may include one or more structures that facilitate thecoupling of insert 30 to the inner surface of sidewall 12. For example,as shown in FIG. 6A, sidewall 12 may include a bead 100 formed insidewall 12. In the embodiment shown, bead 100 is a radially outwardlyextending projection formed in the material of sidewall 12. As such, theinner surface of bead 100 is concave relative to the inner surface ofsidewall 12. It should be understood that in various embodiments, thebeads discussed herein are circumferential beads that extend completelyaround the sidewall of the can. In this embodiment, a portion of theconcave surface of bead 100 is a generally upwardly facing surfaceagainst which insert 30 is seated. Further, insert 30 may be shaped toengage bead 100 to help provide for sufficient seating and to helpensure insert 30 remains fixed within can 10. For example, in theembodiment shown in FIG. 6A, sidewall 34 of disc 32 may be angled inwardrelative to insert 30 and shaped to engage the concave surface of bead100. In one such embodiment, sidewall 34 of insert 30 may be outwardlycurved with the curved sidewall 34 being received within and contactingthe concave inner surface of bead 100. In one embodiment, upstandingwall 34 may be resilient and may snap into bead 100 during insertionsuch that wall 34 engages a portion of the generally downward facingsurface of bead 100. With sidewall 34 snap-fitted into bead 100, thecontact between sidewall 34 and the downwardly facing surface of bead100 acts to resist movement of insert 30 toward upper end of can 10 evenif can 10 is turned upside down, and thereby acts to hold insert 30 inplace within can 10.

Referring to FIG. 6B, sidewall 12 may include an upper bead 110 and alower bead 112. In the embodiment shown, both upper bead 110 and lowerbead 112 are radially inwardly extending projections formed in thematerial of sidewall 12 such that inner surfaces of beads 110 and 112are convex relative to the inner surface of sidewall 12. In thisembodiment, a portion of bead 112 provides a generally upward facingsurface against which insert 30 is seated against. In this embodiment,upstanding wall 34 of insert 30 provides a friction fit against theinner surface of sidewall 12, and the generally downward facing surfaceof bead 110 engages the upper edge of upstanding wall 34 to hold insert30 within can 10 even if can 10 is inverted. In this embodiment,upstanding wall 34 may be resilient such that wall 34 snaps into theregion between beads 110 and 112 during insertion. As shown in FIGS. 6Aand 6B, in some embodiments, sidewall 12 of can 10 may be a non-taperedsidewall, and one or more beads may be used to provide for sufficientengagement with insert 30. In another embodiment, the can sidewall thatincludes beads 100, 110 and/or 112 may be tapered.

Referring to FIG. 6C, a tapered sidewall with transition section 26 mayinclude a radially inwardly extending bead 120. In this embodiment, bead120 is positioned along sidewall 12 above transition section 26. Thelower surface of insert 30 is seated against a generally upwardly facingsurface of transition 26. As shown in FIG. 6C, a generally downwardlyfacing surface of bead 120 engages the upper edge of upstanding wall 34such that insert 30 is held in place even if can 10 is inverted.

Referring to FIG. 6D and FIG. 6E, in one embodiment, insert 30 mayinclude a plurality of locking lugs 130 extending radially outwardlyfrom insert 30, and a corresponding set of recesses 132 are formed insidewall 12 or can 10. Locking lugs 130 are engaged or snap-fitted intorecesses 132 to couple insert 30 within can 10. In the embodiment shownin FIG. 6D and FIG. 6E, locking lugs 130 extend radially outwardly fromthe outer surface of sidewall 34 of insert 30. In one embodiment, duringinsertion of insert 30 into can 10, insert 30 is positioned or rotatedsuch that locking lugs 130 are aligned with recesses 132. While FIG. 6Dshows insert 30 with four locking lugs 130, insert 30 may include 3, 5,6, 7, 8, etc. locking lugs.

Referring to FIG. 7, in another embodiment, the coffee roasting can maybe a two piece can 140 with a tapered sidewall 142. Can 140 is similarto can 10 in many respects, however, can 140 includes a lower end wall144 that is integral with sidewall 142 (i.e., lower end wall 144 andsidewall 142 are formed from a single contiguous piece of metal). In oneembodiment, can 140 includes an insert 30 that is supported within can140 via a friction fit between the inner surface of sidewall 142 and theouter surface of the upstanding sidewall 34 of insert 30. In otherembodiments, can 140 may include any of the insert interface or couplingelements discussed above. In one embodiment, two piece can 140 does notinclude a polymer coating material affixed to either the outside or theinside surface of the metal of the can, and specifically, in oneembodiment, can 140 does not include a polyethylene terephthalate (PET)coating material.

Referring to FIG. 8A-8C, a representation of a process for making can140 having a tapered sidewall 142 is shown using a draw redraw process.As shown in FIG. 8A, a metal blank is drawn or stretched in a first stepin to a partially shaped can body 150. As shown in FIG. 8B, partiallyshaped can body 150 is stretched or drawn in a second step to form astretched can body 152. In one embodiment, following stretching, aflange 154 is formed at the upper end of stretched can body 152. Asdiscussed above, flange 154 is interlocked and crimped with a can end toform a double seam sealing the open upper end of stretched can body 152.As shown in FIG. 8C, can 140 is completed from stretched can body 152 byforming beads into the bottom wall 156 of can body 152 to form beadedlower end wall 144. After can 140 is made via the draw redraw processshown in FIG. 8, an insert 30 is inserted into the interior of can 140as discussed above. In an embodiment in which can 140 does not include aPET coating material, the process for producing can 140 may furtherinclude applying one or more lubricant material to the metal material toallow for proper shaping during the draw redraw process. For example,the metal material that is shaped into can 140 may be temporarily coatedwith a petrolatum material to facilitate shaping of the metal into can140, and in this embodiment, the petrolatum lubricating material maythen be washed or removed from the finished can 140 prior to shipping orfilling of can 140.

FIG. 1 and FIG. 7 each show a coffee roasting can having a taperedsidewall, and as noted above, the tapered sidewall may act to improvefriction fit between the upstanding sidewall of the insert and innersurface of the can sidewall, may provide for nesting during shipment ofempty containers, and may allow for proper engagement with the cavity ofthe roasting device. However, in other embodiments, cans of other shapesmay be used. In various exemplary embodiments, a coffee roasting can maybe shaped as a polygonal prism. In one embodiment, as the can is rotatedduring roasting, the planar sections of sidewall may facilitate mixingof the coffee beans within the can.

Referring to FIG. 9A and FIG. 9B, a polygonal prism shaped coffeeroasting can, can 160, is shown according to an exemplary embodiment.Can 160 is a hexagonal prism shaped can having circular upper and lowercan ends. In one embodiment, the cavity of the roasting appliance may bea polygonal shape to match the polygonal shape of can 160. The matchingconfiguration between the cavity of the roasting appliance and the canmay be used to ensure that can 160 is securely engaged by the roastingappliance prior to rotation. Further, a uniquely shaped can 160 thatmatches the cavity of the roasting appliance may be used to ensure thatonly the proper type of can is used with the roasting appliance.

In other embodiments, a coffee roasting can may include a sidewallhaving a surface feature that engages a mating surface within the cavityof the roasting appliance. Similar to the embodiment discussed above,engagement between the surface feature of the roasting can and thecavity of the roasting appliance may be used to ensure that the propertype of coffee roasting can is used with the roasting appliance.Referring to FIG. 10, an exemplary embodiment of a coffee roasting can170 having a surface feature is shown. Can 170 includes a recessed,surface feature 172 extending around the sidewall of can 170. In otherembodiments, surface feature 172 may include an outwardly projectingfeature that extends outward from the sidewall of the can. In theembodiment shown, surface feature 172 is a wave-like pattern includingupwardly curved and downwardly curved alternating sections. In otherembodiments, surface feature 172 may be other suitable patterns. Forexample, surface feature 172 may be a saw-toothed pattern or may be apattern of surface depressions or dimples.

In various embodiments, the roasting cans and/or cooking cans discussedherein do not include a polymer coating material affixed to either theoutside or the inside surface of the metal of the can. Specifically, invarious embodiments, the cans discussed herein do not include apolyethylene terephthalate (PET) coating or epoxy coating material.Further, the roasting cans and/or cooking cans discussed herein do notinclude sealant compound with the double seams joining the can ends tothe can sidewall. However, in other embodiments, the cans discussedherein are configured to hold food items (e.g., meats, vegetables,fruits, etc.) during cooking and are intended for consumer purchase at agrocery store. In such embodiments, the cans may include an interiorpolymer coating material and/or sealant material within the doubleseams. For cans of this nature, the sealant in the double seamfacilitates creation and maintenance of hermetically seal between thecan sidewall and cab end wall. Further the polymer coating materialprovides a barrier between the container contents and the metal of thecan.

While the embodiments of insert 30 discussed above relate primarily tovarious friction-based couplings between the insert and the innersurface of the sidewall of the container, in other embodiments, othercoupling mechanisms may be used. For example, insert 30 may be coupledto the inner surface of the sidewall of the can by a heat stableadhesive material or by a weld or solder.

In various embodiments, the containers discussed herein may be formedfrom any material, including metals, plastics, ceramics and glasses.According to an exemplary embodiment, the containers and insertsdiscussed herein are formed from metal, such as tin-coated steel oraluminum. In some embodiments, the containers and inserts discussedherein are formed from aluminum and the can ends are formed fromtin-coated steel. In other embodiments, other metals or materials (e.g.,polymers, high-temperature plastic, thermoplastics, cardboard, ceramic,etc.) are used to form some or all of the container.

Containers discussed herein may include containers of a wide variety ofstyles, shapes, sizes, etc. For example, the cans discussed herein maybe shaped such that cross-sections taken perpendicular to thelongitudinal axis of the container are generally circular. However, inother embodiments the sidewall of the containers, such as can 160 andcan 170, discussed herein may be shaped in a variety of ways (e.g.,having other non-polygonal cross-sections, as a rectangular prism, apolygonal prism, any number of irregular shapes, etc.) as may bedesirable for different applications. In various embodiments, the cansidewall may include one or more axially extending sidewall sectionsthat are curved radially inwardly or outwardly such that the diameter ofthe can is different at different places along the axial length of thecan, and such curved sections may be smooth continuous curved sections.The cans may be of various sizes (e.g., 3 oz., 8 oz., 12 oz., 15 oz., 28oz, etc.) as desired for a particular application.

Further, the container ends or can end walls discussed herein may be avariety of suitable walls or closures (e.g., a closure, lid, cap, cover,top, end, can end, sanitary end, “pop-top”, “pull top”, convenience end,convenience lid, pull-off end, easy open end, “EZO” end, etc.). In anexemplary embodiment, the upper can end may be an “EZO” convenience end,sold under the trademark “Quick Top” by Silgan Containers Corp.

The separate upper and lower can ends discussed above are shown and/ordescribed coupled to the can body via a “double seam” formed from theinterlocked portions of material of the can sidewall and the can end.However, in other embodiments, the can ends discussed herein may becoupled to the sidewall via other mechanisms. For example, can ends maybe coupled to the sidewall via welds or solders. In various embodiments,the upper can end may be a closure or lid attached to the body sidewallmechanically (e.g., snap on/off closures, twist on/off closures,tamper-proof closures, snap on/twist off closures, etc.). In anotherembodiment, the upper can end may be coupled to the container body viaan internal vacuum. The container end may be made of metals, such assteel or aluminum, metal foil, plastics, composites, or combinations ofthese materials. In various embodiments, the can ends, double seams, andsidewall of the container are adapted to maintain a hermetic seal afterthe container is filled and sealed.

As discussed above, the containers discussed herein are configured tohold raw coffee beans during roasting using a coffee roasting appliance.It should be understood that the can and insert innovations discussedherein may be utilized in cans configured to hold edible items otherthan coffee beans. For example, the cans and inserts discussed above mayhold nuts, fruits, meats, or vegetables during roasting by a roastingappliance or during cooking in commercial food processing equipment(e.g., a retort). The containers discussed herein may be used to holdperishable materials (e.g., food, drink, pet food, milk-based products,etc.). It should be understood that the phrase “food” used to describevarious embodiments of this disclosure may refer to dry food, moistfood, powder, liquid, or any other drinkable or edible material,regardless of nutritional value.

In various embodiments, the cans discussed herein are configured tocontain foods at a negative internal pressure (e.g., cans that have aninternal vacuum) and the negative internal pressure results in aninwardly directed force on the sidewall of the can. In variousembodiments, the negative internal pressure results from hermeticallysealing the can (e.g., via doubled seamed end walls that the top andbottom of the sidewall) while the contents of the can are hot and fromthe subsequently cooling of the can contents within the hermeticallysealed can. In various embodiments, the cans discussed herein areconfigured to hold contents at an internal vacuum of at least 28pounds/square inch (gauge) or “psig,” and in another embodiment, thecans discussed herein are configured to hold contents at an internalvacuum of at least 22 psig. In other embodiments, the cans discussedherein are filled with food located with the internal cavity of the canand the can is sealed and has an internal vacuum of at least 22 psig, inone embodiment, and at least 28 psig, in another embodiment.

In various exemplary embodiments, the relative dimensions, includingangles, lengths and radii, as shown in the Figures are to scale. Actualmeasurements of the Figures will disclose relative dimensions, anglesand proportions of the various exemplary embodiments. Various exemplaryembodiments extend to various ranges around the absolute and relativedimensions, angles and proportions that may be determined from theFigures. Various exemplary embodiments include any combination of one ormore relative dimensions or angles that may be determined from theFigures. Further, actual dimensions not expressly set out in thisdescription can be determined by using the ratios of dimensions measuredin the Figures in combination with the express dimensions set out inthis description.

Further modifications and alternative embodiments of various aspects ofthe invention will be apparent to those skilled in the art in view ofthis description. Accordingly, this description is to be construed asillustrative only. The construction and arrangements, shown in thevarious exemplary embodiments, are illustrative only. Although only afew embodiments have been described in detail in this disclosure, manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Someelements shown as integrally formed may be constructed of multiple partsor elements, the position of elements may be reversed or otherwisevaried, and the nature or number of discrete elements or positions maybe altered or varied. The order or sequence of any process, logicalalgorithm, or method steps may be varied or re-sequenced according toalternative embodiments. Other substitutions, modifications, changes andomissions may also be made in the design, operating conditions andarrangement of the various exemplary embodiments without departing fromthe scope of the present invention. While the current applicationrecites particular combinations of features in the claims appendedhereto, various embodiments of the invention relate to any combinationof any of the features described herein whether or not such combinationis currently claimed, and any such combination of features may beclaimed in this or future applications. Any of the features, elements,or components of any of the exemplary embodiments discussed above may beused alone or in combination with any of the features, elements, orcomponents of any of the other embodiments discussed above.

For purposes of this disclosure, the term “coupled” means the joining oftwo components directly or indirectly to one another. Such joining maybe stationary in nature or movable in nature. Such joining may beachieved with the two members and any additional intermediate membersbeing integrally formed as a single unitary body with one another orwith the two members or the two members and any additional member beingattached to one another. Such joining may be permanent in nature oralternatively may be removable or releasable in nature.

What is claimed is:
 1. A metal can for holding food during cookingcomprising: a metal sidewall including an upper end, a lower end and amidpoint, the metal sidewall having an inner surface defining aninterior cavity of the can configured to hold food during cooking; ametal can end coupled to the lower end of the sidewall; a metal insertlocated within the interior cavity of the can, the metal insertcomprising a planar disc and an upstanding insert sidewall extendingfrom a peripheral edge of the disc portion, wherein a radially outwardfacing surface of the insert sidewall engages the inner surface of themetal sidewall; and a circumferential bead formed in the metal sidewall,the circumferential bead located between the lower end and the midpointof the metal sidewall, the circumferential bead extending radiallyinward defining a downward facing surface generally facing the lower endof the sidewall; wherein the insert sidewall includes an upward facingsurface generally facing the upper end of the metal sidewall and theupward facing surface of the insert sidewall engages the downward facingsurface of the circumferential bead to hold the metal insert below thecircumferential bead.
 2. The metal can of claim 1 wherein the can end iscoupled to the sidewall by a double seam formed from interlockedportions of the material of the sidewall and the can end.
 3. The metalcan of claim 2 wherein the metal insert is coupled to the inner surfaceof the sidewall via a friction fit.
 4. The metal can of claim 1 whereinthe metal insert extends across the interior cavity of the can to engageopposing portions of the inner surface of the sidewall.
 5. A metal canfor holding coffee beans during roasting comprising: a metal sidewallincluding an upper end and a lower end, the metal sidewall having aninner surface defining an interior cavity of the can configured to holdraw coffee beans during roasting; a can end coupled to the lower end ofthe sidewall; wherein at least a portion of the sidewall is taperedbetween the upper end and lower end of the sidewall.
 6. The metal can ofclaim 5, wherein the can end is coupled to the sidewall by a doubleseam.
 7. The metal can of claim 5, wherein the can end and sidewall areintegrally formed from a single piece of metal.
 8. The metal can ofclaim 5, wherein at least a section of the sidewall is polygonal.
 9. Themetal can of claim 5, wherein the sidewall is round.
 10. The metal canof claim 5, wherein the sidewall includes a feature on the outer surfaceconfigured to engage with a corresponding structure within a cavity of acoffee roasting appliance.
 11. The metal can of claim 10, wherein thefeature is at least one of a wave pattern, a saw-tooth pattern and apattern of dimples formed in the outer surface of the sidewall.
 12. Themetal can of claim 5, further comprising a cup-shaped insert supportedwithin the interior cavity of the can.
 13. The metal can of claim 5,wherein the insert includes a body disc and an upstanding sidewallextending from the peripheral edge of the body disc, and further whereina friction fit between the outer surface of the insert sidewall and theinner surface of the can sidewall supports the insert within theinterior cavity of the can.
 14. The metal can of claim 13, wherein theinsert includes an agitator finger extending from the body disc of theinsert and further wherein the upper edge of the agitator finger iscurved.
 15. The metal can of claim 13, wherein the insert sidewall isperpendicular to the body disc of the insert.
 16. The metal can of claim13, wherein the insert sidewall is at a non-perpendicular angle relativeto the body disc of the insert.
 17. The metal can of claim 13, whereinthe can sidewall includes a bead formed in the sidewall, wherein theinsert engages an inner surface of the bead to support the insert withinthe interior cavity of the can.
 18. The metal can of claim 13, whereinthe insert includes a projection extending from the insert sidewall andthe inner surface of the can sidewall includes a recess that receivesthe projection of the insert.
 19. The metal can of claim 13, wherein theinner surface of the can sidewall includes an upward facing surface andthe insert is seated against the upward facing surface to support theinsert within the interior cavity of the can.
 20. An stirring insertconfigured to be coupled to the inner surface of a sidewall of a metalcan configured to hold raw coffee beans during roasting, comprising: abody disc; a sidewall positioned at the periphery of the body disc andextending away from the body disc; and a stirring finger extending fromthe body disc.
 21. The insert of claim 20, wherein the stirring fingeris integral with the body disc and the sidewall, and further wherein anupper edge of the stirring finger is rounded.
 22. The insert of claim20, wherein the outer surface of the sidewall is configured to form afriction fit engagement with the inner surface of a sidewall of a metalcan such that the insert is supported within the interior of the can.23. The insert of claim 20 further comprising a locking projectionextending radially outward from the insert sidewall and configured toengage a recess located along the inner surface of the can sidewall. 24.A method for producing a stirring insert for a coffee roasting cancomprising: providing a metal blank; forming a body disc and anupstanding sidewall from the metal blank, the upstanding sidewallpositioned at the peripheral edge of the body disc; cutting a slotthrough the body disc, the slot defining the peripheral edge of astirring finger; and pushing the stirring finger upward such that thestirring finger extends away from the body disc.
 25. The method of claim24, wherein the slot is cut using a press.
 26. The method of claim 25,wherein the body disc is supported during cutting of the slot to resistdownward deformation of the body disc during cutting.
 27. A method forproducing a coffee roasting can comprising: providing a rectangularmetal blank; forming a cylinder from the metal blank; shaping thecylinder to form a tapered can sidewall, the sidewall including an openupper end, an open lower end and an upward facing surface located alongthe inner surface of the sidewall; coupling an end wall to the lower endof the sidewall; and inserting a stirring insert through the open upperend of the sidewall such that the insert seats against the upward facingsurface of the sidewall.
 28. The method of claim 27, wherein shapingincludes stretching the cylinder using an expanding mandrel.
 29. Themethod of claim 28, wherein shaping includes radially stretching thecylinder to increase the diameter and decrease the length of thecylinder before stretching using the expanding mandrel.